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Old 02-28-2012, 08:16 PM   #101
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RE: Cat 3208 n.a. coolant leak

I say just the one. I have hardly ever seen an injector line fail. Sounds like yours failed because it was not secured and rubbed against something. Just change one- and you can send me the remaining $490!! No, I changed my mind. I will take some more ginger cookies!! SD, we do a lot of teardowns and over the years I have developed a system that works for me. My memory is terrible, so to begin with I snap digital pictures before and during the tear down. This helps me reconstruct the routing of lines, hoses, wiring, etc. These days I just snap away with my iPhone. Secondly I use telephone wire to mark all hoses, wiring terminals- anything that needs to be reconnected. We keep sections about 10" long of the Multi color telephone wires in the grey outer cover- and anytime I disconnect a starter wire, etc. I cut one of these wires in half and put one on each side. It helps me to remember where things go and it makes the job go faster. The last thing I do is put my fasteners in a Multi compartment tray as I disassemble the project. Iwechave a stack of those Craftsman toolbox plastic drawer inserts that I had the bottom sprayed with truck bedliner. I label each set of bolts. Bellhousing. Starter. Control valve. I'm anal about putting the original hardware back where it belongs. Anyway, what you are doing works great too. This is proven by the fact that she started up and you have been cruising:smile:
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Old 02-28-2012, 08:33 PM   #102
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RE: Cat 3208 n.a. coolant leak

I'm with steve.* Unless they are rust pitted, the chances of the rest of them failing is remote.* Since it leaked at the pipeloom it was probably under stress or*a vibration wear point.* Just check the rest of them at that*clamp and you're good to go.

Larry B*
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Old 02-28-2012, 09:19 PM   #103
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RE: Cat 3208 n.a. coolant leak

Quote:
Forkliftt wrote:
*No, I changed my mind. I will take some more ginger cookies!!

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Some more ginger cookies! What the hell is that? I tried to order some & couldn't! :jawdrop:
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Old 02-29-2012, 04:56 AM   #104
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RE: Cat 3208 n.a. coolant leak

"After a wipe down and a restart that one of the injector lines had developed a leak the red color was rust from the steel line."

This would scare the crap out of me as all that rust is being pumped thru your injectors!

AS a minimum I would pull each and every line and flush them , and change the oil in the injection pump base , and flush IT!!!

Brake cleaner spray will help clean the inside of the delivery tubing.
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Old 02-29-2012, 06:10 AM   #105
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RE: Cat 3208 n.a. coolant leak

Walt
I know SD provides baked goods to the Cruise Ships in Alaska, but down here we have to earn the cookies!! I don't remember exactly how I did this- but I think it included SkipperDude praises and maybe pushing for a SkipperDude Presidential bid???:biggrin:
I DO remember getting my carefully wrapped assortment of Skipperdude cookies in the mail:smile:Ginger is my favorite- but they were all delicious!!
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Old 02-29-2012, 09:08 AM   #106
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Cat 3208 n.a. coolant leak

Quote:
FF wrote:
"After a wipe down and a restart that one of the injector lines had developed a leak the red color was rust from the steel line."

This would scare the crap out of me as all that rust is being pumped thru your injectors!

AS a minimum I would pull each and every line and flush them , and change the oil in the injection pump base , and flush IT!!!

Brake cleaner spray will help clean the inside of the delivery tubing.
*Gotcha FF I will do just that. It troubles me that removing the lines is what caused the leak. The pipeloom as Larry called it ( thanks for the tec term Larry) is where the leak is. I don't think there would be any problem with the injector pump as it is up stream from the leak. Perhaps the adaptor where the injector connects through the head could be an issue.

I bought the tubes for cylinder's 5 and 7 as that is where the leak was

I didn't disassemble it but it was at that pipeloom that the problem occurred. I am going to look at some sort of gasket or insert on the pipeloom *to prevent the vibration from causing this to happen.

On the right side top of the pic is the area where it was leaking.

The second pic is the injector adaptor

Any suggestions?*

SD



-- Edited by skipperdude on Wednesday 29th of February 2012 10:29:32 AM


-- Edited by skipperdude on Wednesday 29th of February 2012 10:46:27 AM
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Old 02-29-2012, 10:16 AM   #107
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Cat 3208 n.a. coolant leak

If you are finding a lot of rust in the fuel that leaked out onto the engine it is unlikely that it came from inside the injector pipe. You will probably cause far more problems removing them again and "cleaning" them.

The failure you experienced is fairly common. It happens because the high pressure pulse tries to straighten the injector tube and unless the clamp (vibration absorber in Cummins speak) is tight enough to restrain the pipe it will oscillate back and forth until it wears through the pipe as you discovered. If there is any moisture around, the shiny worn steel immediately rusts and the superfine particles are spread around the area but are usually invisible unless you wipe the area with a clean white rag or get a lot of liquid diesel fuel on it so that it gets suspended and becomes visible. If you use red dyed fuel, it just looks worse.

Nobody ever checks those clamps bu they should. Any sign of rust at one is a warning flag.

Large engines now have to have the high pressure pipe inside a larger tube so that the spray from a leaking pipe will not cause an explosion and fire when the fog of fuel reaches the exhaust piping. Those larger pipes drain to a small tank that has a level alarm to warn of a leaking injection pipe.


-- Edited by RickB on Wednesday 29th of February 2012 11:17:24 AM
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Old 02-29-2012, 10:57 AM   #108
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RE: Cat 3208 n.a. coolant leak

Thanks Rick. You know I am not even sure it was rust. It was reddish in color.

I did pour a gallon of Marvel mystery oil into the tank as well as a stabilizer for the winter so the fuel may be red in color. I will check it out when next*I am on the boat.

I really didn't get time to tear it apart before the tunnel out of Whittier closed. I will check this all out.

*After looking at the pic I posted I can't see any rust where I found the leak.

I am going to go over all the clamps on the lines and make sure they are tight would you suggest any sort of rubber or gasket to prevent the clamps from wearing the tube away.

*I know Cat does it the way they do but I was thinking of a retrofit to the design.

It is a good thing that I found this because as you say people should be aware of this issue and check it out once in a while as a preventative maintenance.

SD

*
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Old 02-29-2012, 11:23 AM   #109
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RE: Cat 3208 n.a. coolant leak

Quote:
skipperdude wrote:...*would you suggest any sort of rubber or gasket to prevent the clamps from wearing the tube away.
*I would replace old loose ones with factory new. The idea is to eliminate as much vibration as possible and if the old ones are worn and can't hold the pipes tightly together then they should be replaced.

There is a tremendous amount of power in the vibrations and it can cause cracking and leaks at both the pump and injector ends as well as wear at the clamp itself.
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Old 03-03-2012, 07:31 AM   #110
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RE: Cat 3208 n.a. coolant leak

Ditto here. Those engineers should know the best way.
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Old 03-22-2012, 01:44 PM   #111
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RE: Cat 3208 n.a. coolant leak

There was a lot of people that viewed this topic.

*Did anyone really get anything out of it. Other than reading about my bumbling around trying to fix my motor?

It sure helped me a lot as some of the suggestions were right on from the begining.

Are things like this what the forum is about.

Was it a wast of time for anyone?

SD
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Old 03-22-2012, 08:34 PM   #112
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RE: Cat 3208 n.a. coolant leak

Quote:
skipperdude wrote:
There was a lot of people that viewed this topic.

*Did anyone really get anything out of it. Other than reading about my bumbling around trying to fix my motor?

It sure helped me a lot as some of the suggestions were right on from the begining.

Are things like this what the forum is about.

Was it a wast of time for anyone?

SD
*It is not a waste of time if anything that anyone said helped you gain the confidence to do the job.* And that's what seems to have happened.
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Old 03-22-2012, 09:08 PM   #113
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RE: Cat 3208 n.a. coolant leak

I always love following someones efforts at fixing a problem by getting down and getting their own hands dirty.* Nothing worse than listening to people tell*stories of how they paid someone*to do something they could have done*themselves.*

Look how much you learned about your boat and your engine.* I'll bet you have more confidence in your self and your skills now, than before you started this project?* I enjoyed this string very much and was delighted by your success.* Keep it up!!

Larry B
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Old 03-23-2012, 02:18 AM   #114
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RE: Cat 3208 n.a. coolant leak

I find these to be the most enjoyable and educational threads to read. I gain valuable insight following them. I am particularly fond of the input from folks like Rick and others who obviously posses a high degree of knowledge in marine mechanical systems.

SD you are one of the many folks on this board i'd like to have a beer with someday, we seem to share a can do/learn as you go attitude. Sure, its cost me a dollar or two going that route through the years but all education has a price. Couldn't agree more with Larry, if folks have both the time and the aptitude why hire out? There are times when it's prudent and convenient but it's downright boring to hear folks post about. I recently hired out an outboard repair that I just didn't have the time to do but didn't feel compelled to start a thread about it, I did enough writing in my checkbook*
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Old 03-23-2012, 04:43 AM   #115
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RE: Cat 3208 n.a. coolant leak

"Nothing worse than listening to people tell stories of how they paid someone to do something they could have done themselves. "

Not really , many folks understand the problem and the fix , but are reluctant to tackle the job,for lack of experience.

Paying someone , and watching over their shoulder , Monkey See Monkey Do can show folks how easy the job really is.

It is a good technique for folks starting . or that can not understand Da Book,for lack of experience.
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Old 03-23-2012, 06:50 AM   #116
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RE: Cat 3208 n.a. coolant leak

Quote:
CPseudonym wrote:SD you are one of the many folks on this board i'd like to have a beer with someday, we seem to share a can do/learn as you go attitude.
Tell the truth.* You just want to get your hands on some of his Oatmeal Cookies.
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Old 03-23-2012, 10:39 AM   #117
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Cat 3208 n.a. coolant leak

Thanks for the accolades I wasn't really looking for that but appreciated.

*It was kind of a long thread over 4,000 people looked in to see what was happening. As it started with a coolant leak and morphed into a rebuild.

I was just hoping someone learned something from all the questions and answers.

When it comes right down to it it was just nuts and bolts with a little grunting and groaning because of the heavy parts.

It's like if I could do it anybody can.

Like Larry of Edelwisse said "*You have more confidence in your self and your skills now, than before you started this project."

I sure do.

What I am trying to say is Jump in with both feet and Get er done. Adjust your valves. Keep up on the maintenance.

Know your boat systems. What happens if you are out there somewhere and something go's wrong. You have to be able to fix things.

Like I always say " If you cant fix it maybe it shouldn't be on the boat."

The forum was a great help and offered a boat load of encourigement.

Thanks to all.

SD

*


-- Edited by skipperdude on Friday 23rd of March 2012 10:47:19 AM
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Old 03-23-2012, 04:17 PM   #118
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RE: Cat 3208 n.a. coolant leak

Quote:
JD wrote:CPseudonym wrote:SD you are one of the many folks on this board i'd like to have a beer with someday, we seem to share a can do/learn as you go attitude.
Tell the truth.* You just want to get your hands on some of his Oatmeal Cookies.

*Oatmeal cookies would be good too. But if I shake him down for anything it would be some of those crab he posted the other day
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Old 03-24-2012, 03:26 AM   #119
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RE: Cat 3208 n.a. coolant leak

Oatmeal cookies?

Was that with the "Alice B Toklas" recipe?
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Old 06-09-2012, 07:49 PM   #120
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It was worthy it!

Quote:
Originally Posted by skipperdude View Post
There was a lot of people that viewed this topic.

*Did anyone really get anything out of it. Other than reading about my bumbling around trying to fix my motor?

It sure helped me a lot as some of the suggestions were right on from the begining.

Are things like this what the forum is about.

Was it a wast of time for anyone?

SD
I often tell the SO that reading these forums is better than reading a first rate novel.
I WAS INTRIGUED to find out how your project ended! It was a great read, informative and gave me the encouragement to tackle lesser jobs. Hopefully I will work my way up to ones of your difficulty level.
Keep up the great information sessions. Obviously, there are many who enjoy it. Hopefully other enterprising boaters will also be encouraged to share their experiences.

CWORTHY
"Boatless in NS"
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